Numerically controlled cross-tie pre-plating system

ABSTRACT

A machine for fastening rail plates to cross-ties, utilizing spikes or the like, and method therefore, is disclosed in the present invention. The present invention further is configured to facilitate the installation of threaded spikes or screws, as are utilized in high-speed, concrete and other cross-ties. A numerically controlled drilling station is therefore provided for selectively positioning a drill about the length of the cross-tie for drilling bores into the tie, along with a separate screwed pre-plating station which may include a template for positioning the tie, a plate dispenser (or manual plate loading means), and a positionable driving mechanisms for engaging and screwing threaded spikes or screws into the bores formed by the drilling station to securely pre-plate each plate on a tie, which may be wood or concrete, traditional or high-speed. The present system is particularly suitable for pre-plating cross-tie for forming turnouts, which require that each tie along a curve be drilled in a separate location. Accordingly, utilizing CAD or other input information, a computer can automatically control the numerically controlled drill station to drill out each tie to form the desired turnout, greatly reducing the time, expense, and risk associated with this procedure.

STATEMENT OF CONTINUING APPLICATIONS

[0001] The present application is a Continuation of Provisional PatentApplication Serial No. 60/328,732 filed Oct. 11, 2001. This applicationis also a Continuation-in-part of U.S. patent application Ser. No.09/689,330 filed Oct. 12, 2000, which is a divisional of U.S. Pat. No.6,131,272 issued Oct. 17, 2000, filed Mar. 22, 1999, which is acontinuation-in-part of U.S. patent application Ser. No. 09/161,135,filed Sep. 25, 1998, listing as inventors Gerald D. Girouard, Sr.,Gerald D. Girouard, Jr., and Donald Darcey, which is a continuation ofU.S patent application Ser. No. 08/665,670, U.S. Pat. No. 5,813,103,filed Jun. 20, 1996, entitled “Cross-Tie Pre-Plating System”, listing asinventors Gerald D. Girouard, Sr., Gerald D. Girouard, Jr., and DonaldDarcey, which patent is a continuation of Ser. No. 300,749, U.S. Pat.No. 5,528,807, issued Jun. 25, 1996, filed Sep. 6, 1994, entitled“Cross-Tie Pre-Plating System”, listing as inventors Gerald D. Girouard,Sr., Gerald D. Girouard, Jr., and Donald Darcey, which patent is acontinuation of U.S. patent application Ser. No. 207,118, U.S. Pat. No.5,343,606, issued Sep. 6, 1994, filed Feb. 28, 1994, entitled “Cross-tiePre-Plating System”, listing as inventors Gerald D. Girouard, Sr.,Gerald D. Girouard, Jr., and Donald Darcey, which patent is acontinuation of U.S. patent application Ser. No. 08/085,400, filed Jun.30, 1993, now abandoned.

TECHNICAL FIELD OF THE INVENTION

[0002] The present invention relates to Railroad construction apparatus,and in particular to a machine for fastening rail plates to cross-ties,utilizing spikes or the like, and method therefore, is disclosed in thepresent invention.

[0003] The preferred apparatus of the present invention teaches a systemwherein there is provided a conveyor for conveying a plurality oflaterally arranged, juxtaposed ties, a loader or kicker for loading asingle tie upon a template conveyer, and positioning means forpositioning a single tie at each station during the pre-plating process.

[0004] The present invention further may include a template system forsecuring the cross-tie or tie in place, feeding and positioning therail-plate(s) in place, feeding, dispensing, and positioning the spikesin place, driving the spikes, and discharging the processed tie, thetemplate system utilizing reciprocating drive pistons for positioningthe template, as well as dispensing the plates.

[0005] The present invention further is configured to facilitate theinstallation of threaded spikes or screws, as are utilized inhigh-speed, concrete and other cross-ties. A numerically controlleddrilling station is therefore provided for selectively positioning adrill about the length of the cross-tie for drilling bores into the tie,along with a separate screwed pre-plating station which may include atemplate for positioning the tie, a plate dispenser (or manual plateloading means), and a positionable driving mechanisms for engaging andscrewing threaded spikes or screws into the bores formed by the drillingstation to securely pre-plate each plate on a tie, which may be wood orconcrete, traditional or high-speed.

[0006] The present system is particularly suitable for pre-platingcross-tie for forming turnouts, which require that each tie along acurve be drilled in a separate location. Accordingly, utilizing CAD orother input information, a computer can automatically control thenumerically controlled drill station to drill out each tie to form thedesired turnout, greatly reducing the time, expense, and risk associatedwith this procedure.

[0007] The present invention is unique in its relative simplicity whencompared to prior art systems, providing a full array of pre-platingcapabilities utilizing standard spikes or threaded means, various sizedand composition cross-ties, on a relatively compact and roadtransportable, mobile platform.

GENERAL SUMMARY DISCUSSION OF THE INVENTION

[0008] Unlike the prior art, the present invention provides railroad-tiepre-plating system which is comparatively low maintenance and reliable,while being relatively inexpensive to manufacture, flexible in the typeof fastening means, plate and tie configuration, size, and materialutilized, while being consistent in cycle time and output quality.

[0009] The preferred embodiment of the present invention teaches asystem wherein there is included:

[0010] Feed means for feeding the cross ties in bulk via declinerollers;

[0011] Retrieval means for retrieving an individual cross-tie from thegravity feed;

[0012] A first station comprising a numerically controlled drillingtemplate and drilling means for providing precise bores which can varyfrom tie-to tie in forming such complex layouts as utilized in curves,turn-outs or the like, which bores are for the insertion of threadedspikes or screws therein.

[0013] A second station, comprising a driving station with manuallypositionable racheting or screwing machines is provided so as to allowoperators(s) to manually load a plate upon the tie in the vicinity ofthe bores formed at the first station, align the plate in relation tothe bores, and drive screws through the plates into the bores so as tofasten the plate(s) to the tie.

[0014] Discharge means for removing the pre-plated cross tie forstacking.

[0015] Unlike the prior art, the present invention contemplates a systemwherein all of the various elements interrelate in function andoperation, providing a more efficient, less redundant apparatus. Assuch, the present invention as currently configured in a workingembodiment is capable of pre-plating multiple custom-drilled tie via thenumerically controlled drill station with a cycle time of a typical 24foot tie within three minutes, the actual cycle time varying dependingupon the differences in the positioning of the drill holes on the ties,the amount of holes, the type of screws, and the size of the tie.

[0016] This is compared to a manual crew of five workers, whichtypically must take breaks on the hour (more on hot days), and mustmanually measure the position of custom drilled holes, which accountsfor far more time and less accuracy than the present system.

[0017] Unlike prior art pre-plating mechanisms for fastening viathreaded spikes, which required a highly specialized, generally fixed,slow, and expensive system, the present preferred embodiment of theinvention contemplates a pre-plating system which provides unsurpassedflexibility over the prior art, teaching a mechanism and process whichallows for pre-plating of most types of cross-ties, utilizing threadedspikes, in a fast, relatively inexpensive manner.

[0018] While the system may be fixed or relatively portable, and able tobe transported via road to a production site in three, readily assembledpieces on a flatbed trailers, an alternative embodiment of the presentinvention teaches a version of the invention wherein the mainconveyor/pre-plating area of the apparatus is located on a railroad flatcar.

[0019] It is therefore an object of the present invention to provide arailroad cross-tie pre-plating system which is relatively simple inoperation, yet efficient, reliable, and inexpensive to operate.

[0020] It is another object of the present invention to provide arailroad cross-tie pre-plating system which is able to be operated by ateam of three to five workers.

[0021] It is still another object of the present invention to provide arailroad cross-tie pre-plating system which provides a per unit totalcycle of three minutes or less.

[0022] It is another object of the present invention to provide arailroad cross-tie pre-plating system which fastens plates to cross-tiesvia threaded spikes, on a variety of sized cross-ties.

[0023] Finally, it is an object of the present invention to provide arailroad cross-tie pre-plating system which allows for quick, automateddrilling of custom-drilled ties as is used in railroad turns orturn-outs.

BRIEF DESCRIPTION OF DRAWINGS

[0024] For a further understanding of the nature and objects of thepresent invention, reference should be had to the following detaileddescription, taken in conjunction with the accompanying drawings, inwhich like parts are given like reference numerals, and wherein:

[0025]FIG. 1 is an isometric view of the preferred embodiment of thenumerical controlled drilling station/cross-tie pre-plating system ofthe present invention, illustrating the layout of the two mainoperations stages for processing the ties of the present invention,interconnected by a processing conveyor having first and second ends,the cross-tie loading and unloading ramps communicating with said firstand second ends, respectively.

[0026]FIGS. 2A and 2B are end views of the loading ramp and CNCcontrolled, single bit cross-tie boring system of the present invention.

[0027]FIG. 3 is an end-close-up view of the invention of FIGS. 2A and2B.

[0028]FIGS. 4A, 4B, 4C, and 4D offer end views of the manually operatedthreaded fastening system of the present invention.

[0029]FIG. 5 is an end, close-up view of the invention of FIGS. 4A-4D.

DETAILED DISCUSSION OF THE INVENTION

[0030] Referring to FIG. 1 of the drawings, the cross-tie pre-platingsystem of the present invention I comprises an elongated base B, which,in the preferred embodiment of the present invention may compriseseparate work areas and platforms or first and second a modified flatbedtrailer(s) or railcar(s), or other non-mobile or mobile platform

[0031] As shown, the base B has a top surface 3, first 1 and second 2ends, and a longitudinal axis 4 which has aligned therewith a horizontalconveyor 5 along top surface 2, the top surface further having first 6and second 7 ends situated in agreement with the first 1 and second 2ends of base, respectively. Situated along the length of the conveyor 5is a plurality of generally even spaced rollers 8 which may be engagedto one another via chains or belts, and which are powered to rotate viamotor or the like, in order to selectively convey a cross-tie C alongthe length of the conveyor during pre-plating operations, transportingthe cross-tie C from station to another, and depositing same from theconveyor after operations, or may be independently driven my electricalpneumatic, or hydraulic motors or the like.

[0032] As shown, a plurality of un-plated cross-ties 14 are loaded upona loading conveyor 13, which may be a gravity conveyor type (i.e., theend distal the horizontal conveyor is higher than the end closest thehorizontal conveyor, with rollers thereupon to facilitate movement ofthe ties towards the horizontal conveyor 5) or the like configured tourge the ties placed thereupon, in laterally aligned fashion upon theconveyor, to urge the ties towards the horizontal conveyor 5 where theties are loaded 15 upon the horizontal conveyor one at a time.

[0033] The ties are selectively loaded upon the horizontal conveyor 5via a loading mechanism; once loaded upon the horizontal conveyor 5,each tie is then processed by, a first drilling station 9 for drillingpilot holes, which may comprise drilling apparatus which may bedynamically positioned via numerical control for forming bores which areutilized in driving lag or coach screws or the like for fastening theplates to the ties at a separate driving station 11 for driving threadedfasteners through manually positioned and aligned plates into the ties.

[0034] The unit is principally automated and controlled by a computerand an operator controlled 20 at a main operating station 19, shownlocated generally centrally of the system to enable monitoring of allactivities.

[0035] Once each tie C is processed at stations 9, 11, the tie C havingtraversed the horizontal conveyor 5 to the second end 7 is thendeposited 18 upon unloading ramp 16, which may be a gravity conveyordownwardly directed from the horizontal conveyor, where each tieprocessed tie is urged to the distal end 16′ of same, such that the tiesare loaded upon the ramp 16, where the processed ties are situated inaligned fashion lateral to the ramp, ready for lifting via forklift orthe like for further transport or processing.

[0036] Continuing with FIGS. 1, 2A, 2B, and 3, the loading ramp 13 orconveyor is, as indicated, a gravity type, wherein the first end 13′ oframp distal to the conveyor 5 is higher than the second end 13″ of rampadjacent to conveyor 5, with rollers 13 situated along the length of theupper section of the ramp to facilitate gravity transfer to thecross-ties 14 (tie, cross-ties, and railroad cross-ties are intendedthroughout this document to have the same meaning) along the length oframp 13.

[0037] As shown, the ties 14 are dispensed individually to thehorizontal conveyor 5 via the second, lower end 13″ of the loading ramp13, which utilizes a blocking member 40′, configured to hold back thebulk of railroad ties and allow for the dispensing of a single loadedtie 35 upon demand. When a tie is desired to be loaded upon thehorizontal conveyor for processing, as shown, a reciprocating piston 40is actuated, lifting 39 a loading bar or kicker 36 at an angle, liftingthe tie 35 on the kicker above blocking member 40′, while urging viagravity the tie along the rollers over blocking member 40′, alonglifting bar and upon the conveyor 5.

[0038] Concurrent with the loading of tie 35 onto conveyor, the secondend 38 of the loading bar is lifted to also facilitate blocking 41 ofthe next tie to be dispensed 34, preventing the remaining ties fromadvancing uncontrollably upon the conveyor 5. Once the tie 35 is loaded,the loading bar 36 is lowered 43, allowing the next tie 34 to advance 44over rollers to blocking member 40′ as shown in FIG. 3B. A proximityswitch and/or timer circuit may be utilized to facilitate the loweringof the loading bar, as the tie is loaded, allowing the next tie 34 to bedispensed to advance to the loading position 45 adjacent to blockingmember 40′.

[0039] Continuing with the FIGS. 1, 4A-4D, and 5, the drilling stationcomprises a track mounted motor which is preferably at this timeelectric, but may also be hydraulic or pneumatic the motor having x-ymovement along the track for positioning the drill bit anywhere alongthe length of the cross-tie, as dictated by coordinates inputted to acomputer which drives a positioning motor associated with the drillingunit to propel the drill along x-y coordinates along the track. Further,the drill is vertically manipulated (z coordinates during the drillingprocedure, so the system is automatically positioned via x, y and zaxis, as dictated by the instructions provided to the control computer.

[0040] The Z axis manipulation of the drilling unit may be via rack andpinion with a driving motor, or via reciprocating piston or other means,so as so as to lift the drill bit such that it is in a clear fashionduring positioning of the tie to be drilled.

[0041] The computer numerically controlled (CNC) drilling station reliesupon coordinates of each bore to be made into the beam, which arerelayed to the CNC system for positioning the drilling apparatus alongx-y coordinates via gantry or the like.

[0042] Once pilot bores have been formed in the tie, the tie is directedto the second, threaded fastener or driving station 11, where plates aremanually placed, and a manually positioned 106 screw driving arrayslidingly engaged to vertical support members 107 and which screwdriving array 106 is lifted 112 and lowered 111 vertically eithermanually utilizing a counterbalance, or via mechanical other means suchas a reciprocating piston.

[0043] As shown, the screw driving array 106 includes two front 106′,and two rear 106″, motorized screw holding and driving mechanisms,comprising eight screw driving/holding mechanism total, spaced to drivetwo spaced sets of four screws each, in order to drive each set of foursscrews in precise manner through screw passages formed in a singleplate. Further, the screw driving array is situated along a track toposition said array anywhere along the longitudinal axis of the tie tobe plated, wherein it can be manually positioned by hand or via amotorized control.

[0044] The screw driving array 106 in the present system therebyfacilitates the insertion of screws through a single plate at a timealong a tie.

[0045] Continuing with the figures, each screw driving system comprisesa screw holder 114, 114′, which in the preferred embodiment of thepresent invention is configured each to have a magnet 125 embeddedtherein to magnetically engage and support the head of a lag screw 113,respectively, which lag screws are loaded in the present embodiment totheir respective screw holders manually. The front screw holders 114 aresupported by an extension 115 configured to engage motors 116, which aresituated in spaced, forward relationship above rear motors 117 of therear screw driving mechanisms, which motors rear motors 117 may beattached directly to screw holders 114′ without an extension.

[0046] The front motors 116 are supported by upper, independenthorizontal support members 118, while the rear motors 117, 117′ aresupported by lower horizontal support members 119, respectively, whichin turn slidingly engage vertical support members 107.

[0047] In operation, the operator would allow the pre-bored tie 136(pilot boring accomplished at the first, drilling station) under theraised template 149, which is then longitudinally via control 154. Afterpositioning, the plates are either automatically dispensed or manuallypositioned into alignment with the bored holes.

[0048] The operator then, by hand loads the lag screws 113, 113′, to thescrew holders, and then may apply grease to the threads of same tofacilitate easier insertion, and then initiates motors 116, 117, thenlowering rotating screws via piston 110 communicating with horizontalsupport bar via control 154.

[0049] As shown in the figures, the front screws 113 engage the frontscrew passages formed in tie 135 first, passing through said passagesand into pilot bores pre-formed thereunder, with the rear screws 113′thereafter lowering and boring 145 into their respective screw passagesand pre-formed pilot bores thereunder, until the lag screw heads engagethe tops of the plates, providing screwed lag screws on a fastened plateto tie 136. The screw driving apparatus is then lifted 153 via piston110, completing screwed fastening of the plate to the tie.

[0050] Continuing with the figures, the processed tie is urged via theconveyor to the second end 7 of the horizontal conveyor 5, wherein it isdischarged to the unloading ramp.

Exemplary Specifications

[0051] Drilling Station

[0052] Drill head: belt driven 10 HP AC Motor; variable speed up to 6 kRPM; quick change spindle for changing bit. Drill head to travel along30 foot track having x-y axle servo motor drive with brakes, having 0 to600 inches per minute travel on all axis.

[0053] Drill Bits—First Station: Size: {fraction (11/16)}+− (varies);Configured Depth of Bore: 8″ or less (varies);

[0054] Machine control: Fagor Model 8055 CNC Control with 12 inch LCDscreen mounted on a pendant on machine to control all functionsutilizing built in programmable logic controller internal to the FAGORCNC control.

[0055] Servo: Three Fagor AC digital servo motors with brakes for axisdrives utilizing encoder fee from servo motor on y-z axis. X Axis willutilize a Fagor steel stretched scale for feedback/rack and pinionmechanical interface.

[0056] Screw Driving Station

[0057] Three Station machine for driving lag screws or the like intobore holes {fraction (11/16)}+− in diameter.

[0058] Machine Control: Can be manually or machine controlled, utilizingtwo axis, X axis can be positioned via hydraulic motor rack (for example400 inches/minute) with pinion driven position with a joystick by eye.

[0059] Screw motors via hydraulic motors/power pack system.

[0060] Driver: hydraulic motor at 100 RPM with variable torque.

[0061] Screw type: Lag Screw, diameter: varies, length:varies.

[0062] Conveyor

[0063] Horizontal Conveyor Length: 30′; Width:12″

[0064] In summary, the method of the preferred embodiment of the presentinvention comprises fastening a plate to a cross-tie, comprising thesteps of:

[0065] a) loading a tie upon a horizontal conveyor, providing a loadedtie;

[0066] b) providing pre-existing x-y coordinate instructions to acomputer control for designating locations upon said tie to be bored,thereby providing borehole data;

[0067] c) positioning said tie at a boring station;

[0068] d) utilizing said x-y coordinates to position a numericallycontrolled drill along a track longitudinally aligned with said loadedtie to a first bore coordinate;

[0069] e) automatically actuating and lowering said drill to bore a holeat said first bore coordinate;

[0070] f) utilizing said x-y coordinates to position said numericallydrill along said track to a next bore coordinate for said loaded tie;

[0071] g) automatically actuating and lowering said drill to bore a holeat said next bore coordinate;

[0072] h) repeating steps f) and g) until all of said pre-existing x-ycoordinate borehole data for said loaded tie has been utilized,providing a bored tie;

[0073] l) loading the next tie to be drilled, providing the next loadedtie;

[0074] j) repeating steps b-h, while

[0075] k) conveying said bored tie to a screwing station.

[0076] c) forming pilot bores into said aligned, loaded tie with saidboring apparatus, providing a bored tie;

[0077] d) conveying said bored tie to a pre-plating apparatus;

[0078] e) utilizing a template having first and second plate traysformed therein to align said bored tie such that said first and secondplate trays are adjacent to the ends of first and second plateconveyors, respectively;

[0079] f) dispensing first and second plates from said first and secondplate trays such that said first and second plates fall into said firstand second plate trays, respectively, and rest upon said bored tie suchthat at least some of apertures formed in said dispensed plates arealigned with said pilot bores formed in said bored tie;

[0080] g) fastening said dispensed plates to said tie by applying afastener through said apertures formed in said plates aligned with saidpilot bores formed in said tie, providing a pre-plated tie;

[0081] h) dispensing said pre-plated tie from said horizontal conveyor.

[0082] I) providing a plate having apertures formed therethrough uponsaid bored tie

[0083] ii) aligning said apertures formed through said dispensed plateswith said bores formed in said loaded tie; and

[0084] driving a screw through each of said aligned apertures formedthrough each of said dispensed plates and said aligned pilot bore formedin said loaded tie thereunder, fastening said plate to said tie.

[0085] The invention embodiments herein described are done so in detailfor exemplary purposes only, and may be subject to many differentvariations in design, structure, application and operation methodology.Thus, the detailed disclosures therein should be interpreted in anillustrative, exemplary manner, and not in a limited sense.

What is claimed is:
 1. The method of fastening a plate to a cross-tie,comprising the steps of: a) loading a tie upon a horizontal conveyor,providing a loaded tie; b) providing pre-existing x-y coordinateinstructions to a computer control for designating locations upon saidtie to be bored, thereby providing borehole data; c) positioning saidtie at a boring station; d) utilizing said x-y coordinates to position anumerically controlled drill along a track longitudinally aligned withsaid loaded tie to a first bore coordinate; e) automatically actuatingand lowering said drill to bore a hole at said first bore coordinate; F)utilizing said x-y coordinates to position said numerically drill alongsaid track to a next bore coordinate for said loaded tie; g)automatically actuating and lowering said drill to bore a hole at saidnext bore coordinate; h) repeating steps f) and g) until all of saidpre-existing x-y coordinate borehole data for said loaded tie has beenutilized, providing a bored tie; I) loading the next tie to be drilled,providing the next loaded tie; j) repeating steps b-h, while k)conveying said bored tie to a screwing station. c) forming pilot boresinto said aligned, loaded tie with said boring apparatus, providing abored tie; d) conveying said bored tie to a pre-plating apparatus; e)utilizing a template having first and second plate trays formed thereinto align said bored tie such that said first and second plate trays areadjacent to the ends of first and second plate conveyors, respectively;f) dispensing first and second plates from said first and second platetrays such that said first and second plates fall into said first andsecond plate trays, respectively, and rest upon said bored tie such thatat least some of apertures formed in said dispensed plates are alignedwith said pilot bores formed in said bored tie; g) fastening saiddispensed plates to said tie by applying a fastener through saidapertures formed in said plates aligned with said pilot bores formed insaid tie, providing a pre-plated tie; h) dispensing said pre-plated tiefrom said horizontal conveyor.
 2. The method of claim 1, wherein afterstep “I” there is included the additional steps of: I) providing a platehaving apertures formed therethrough upon said bored tie ii) aligningsaid apertures formed through said dispensed plates with said boresformed in said loaded tie; and driving a screw through each of saidaligned apertures formed through each of said dispensed plates and saidaligned pilot bore formed in said loaded tie thereunder, fastening saidplate to said tie.